Flame resistant fabrics

ABSTRACT

Embodiments of the present invention relate to flame resistant fabrics formed with inherently flame resistant fibers that provide the requisite thermal and arc protection, that have improved comfort, and that, in some embodiments, are less expensive than other fabrics formed with inherently flame resistant fibers. Improved comfort and lower cost can be achieved by predominantly locating the inherently flame resistant fibers on the front face of the fabric to impart the requisite thermal and arc protection and predominantly locating the more comfortable (and less expensive) fibers on the back face of the fabric positioned next to the wearer. In this way, overall protection of the fabric is maintained while improving comfort. Some embodiments of such fabrics may also achieve NFPA 70E PPE Category 2 protection.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/825,350, filed Mar. 28, 2019 and entitled “Low Cost Flame ResistantFabrics with Inherently Flame Resistant Fibers,” the entirety of whichis hereby incorporated by reference.

FIELD OF THE INVENTION

Embodiments of the present invention relates to low cost and low weightflame resistant protective fabrics and garments made therefrom thatimpart improved protection to the wearer.

BACKGROUND

Many occupations can potentially expose an individual to electrical arcflash and/or flames. Workers who may be exposed to accidental electricarc flash and/or flames risk serious burn injury unless they areproperly protected. To avoid being injured while working in suchconditions, these individuals typically wear protective garmentsconstructed of flame resistant materials designed to protect them fromelectrical arc flash and/or flames. Such protective clothing can includevarious garments, for example, coveralls, pants, and shirts. Standardshave been promulgated that govern the performance of such garments (orconstituent layers or parts of such garments) to ensure that thegarments sufficiently protect the wearer in hazardous situations.Fabrics from which such garments are constructed, and consequently theresulting garments as well, are required to pass a variety of safetyand/or performance standards, including ASTM F1506, NFPA 70E, NFPA 2112,and NFPA 1975.

AS™ F1506 (Standard Performance Specification for Flame Resistant andArc Rated Textile Materials for Wearing Apparel for Use by ElectricalWorkers Exposed to Momentary Electric Arc and Related Thermal Hazards,2018 edition, incorporated herein by reference) requires arc ratingtesting of protective fabrics worn by electrical workers. The arc ratingvalue represents a fabric's performance when exposed to an electricalarc discharge. The arc rating is expressed in cal/cm² (calories persquare centimeter) and is derived from the determined value of the arcthermal performance value (ATPV) or Energy Breakopen threshold (EBT).ATPV is defined as the arc incident energy on a material that results ina 50% probability that sufficient heat transfer through the specimen ispredicted to cause the onset of second-degree burn injury based on theStoll Curve. EBT is the arc incident energy on a material that resultsin a 50% probability of breakopen. Breakopen is defined as any open areain the material at least 1.6 cm² (0.5 in.²). The arc rating of amaterial is reported as either ATPV or EBT, whichever is the lowervalue. The ATPV and EBT is determined pursuant to the testingmethodology set forth in AS™ F1959 (Standard Test Method for Determiningthe Arc Rating of Materials for Clothing, 2014 edition, incorporatedherein by reference), where sensors measure thermal energy properties ofprotective fabric specimens during exposure to a series of electricarcs.

NFPA 70E (Standard for Electrical Safety in the Workplace, 2018 edition,incorporated herein by reference) offers a method to match protectiveclothing to potential exposure levels incorporating Personal ProtectiveEquipment (PPE) Categories. Protective fabrics are tested to determinetheir arc rating, and the measured arc rating determines the PPECategory for a fabric as follows:

PPE Category and ATPV

PPE Category 1: ATPV/E_(BT): 4 cal/cm²

PPE Category 2: ATPV/E_(BT): 8 cal/cm²

PPE Category 3: ATPV/E_(BT): 25 cal/cm²

PPE Category 4: ATPV/E_(BT): 40 cal/cm²

Thus, NFPA 70E dictates the level of protection a fabric must possess tobe worn by workers in certain environments.

NFPA 2112 (Standard on Flame-Resistant Clothing for Protection ofIndustrial Personnel Against Flash Fire, 2018 edition, incorporatedherein by reference) governs the required performance of industrialworker garments that protect against flash fires. NFPA 1975 (Standard onEmergency Services Work Apparel, 2014 edition, incorporated herein byreference) governs the required performance of station wear worn byfirefighter's in the firehouse and under turnout gear. NFPA 2112, AS™F1506, and NFPA 1975 all require that the garments and/or individuallayers or parts thereof pass a number of different performance tests,including compliance with the thermal protective requirements of havinga char length of 4 inches or less (NFPA 2112) or 6 inches or less (AS™F1506 and NFPA 1975) and of having a two second (or less) afterflame(NFPA 2112, AS™ F1506, and NFPA 1975), when measured pursuant to thetesting methodology set forth in AS™ D6413 (Standard Test Method forFlame Resistance of Textiles, 2015 edition, incorporated herein byreference).

To test for char length and afterflame, a fabric specimen is suspendedvertically over a flame for twelve seconds. The fabric mustself-extinguish within two seconds (i.e., it must have a 2 second orless afterflame). After the fabric self-extinguishes, a specified amountof weight is attached to the fabric and the fabric lifted so that theweight is suspended from the fabric. The fabric will typically tearalong the charred portion of the fabric. The length of the tear (i.e.,the char length) must be 4 inches or less (AS™ 2112) or 6 inches or less(AS™ F1506 and NFPA 1975) when the test is performed in both themachine/warp and cross-machine/weft directions of the fabric. A fabricsample is typically tested for compliance both before it has been washed(and thus when the fabric still contains residual—and oftenflammable—chemicals from finishing processes) and after a certain numberof launderings (e.g., 100 launderings for NFPA 2112 and 25 launderingsfor AS™ F1506).

NFPA 2112 and NFPA 1975 also contain requirements relating to the extentto which the fabric shrinks when subjected to heat. To conduct thermalshrinkage testing, marks are made on the fabric a distance from eachother in both the machine/warp and cross-machine/weft directions. Thedistance between sets of marks is noted. The fabric is then suspended ina 500 degree Fahrenheit oven for 5 minutes. The distance between sets ofmarks is then re-measured. The thermal shrinkage of the fabric is thencalculated as the percentage that the fabric shrinks in both themachine/warp and cross-machine/weft directions and must be less than thepercentage set forth in the applicable standard. For example, NFPA 2112and NFPA 1975 require that fabrics used in the construction of flameresistant garments exhibit thermal shrinkage of no more than 10% in boththe machine/warp and cross-machine/weft directions.

NFPA 1975 further contains a thermal stability standard. To test forthermal stability, a fabric sample is folded and inserted between twoglass plates. The sandwich is then put in an oven at a specifiedtemperature and for a specified time. After heating, the fabric ispulled apart. If the fabric sticks to itself, it fails the thermalstability test.

In the oil, gas, electric utility, and fire safety markets, there is aneed for inexpensive, lightweight flame resistant fabrics that achieve ahigh arc rating while still complying with all applicable thermalprotective requirements. More specifically, there is a need forinexpensive, lighter weight protective fabrics that achieve NFPA 70E PPECategory 2 protection (8 cal/cm² arc rating). Due to high temperatureworking conditions in some workplaces, end users also have a need forcomfortable (e.g., breathable) protective fabrics that have excellentmoisture management properties (e.g., wicking).

Historically, such fabrics have been formed from identical yarns madeexclusively from cellulosic fibers treated with a chemical (e.g.,phosphorous) to render them flame resistant. Cellulosic fibers arecheap, lightweight, and soft, thus rendering the fabrics into which theyare incorporated inexpensive and comfortable. However, the flameresistance of these fibers is not inherent to the fibers themselves.Rather, the fibers must be chemically-treated to impart flame resistanceto them. If the fibers are not treated properly, the chemicals can washout of the fibers and thereby significantly diminish the flame resistantproperties of the fibers and thus the fabrics and garments into whichthey are incorporated. Existing fabrics formed with inherently flameresistant fibers that do not suffer from this same drawback are moreexpensive and harsher to the touch. Thus, such fabrics have been unableto compete successfully in this space. There is a need for acomfortable, lightweight, inexpensive fabric formed with inherentlyflame resistant fibers that affords the requisite thermal and arcprotection.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this patent are intended to refer broadly toall of the subject matter of this patent and the patent claims below.Statements containing these terms should not be understood to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below. Embodiments of the invention covered by this patentare defined by the claims below, not this summary. This summary is ahigh-level overview of various aspects of the invention and introducessome of the concepts that are further described in the DetailedDescription section below. This summary is not intended to identify keyor essential features of the claimed subject matter, nor is it intendedto be used in isolation to determine the scope of the claimed subjectmatter. The subject matter should be understood by reference to theentire specification of this patent, all drawings and each claim.

Embodiments of the present invention relate to flame resistant fabricsformed with inherently flame resistant fibers that provide the requisitethermal and arc protection but that are less expensive than otherfabrics formed with inherently flame resistant fibers and that haveimproved comfort. Improved comfort and lower cost can be achieved bypredominantly locating the inherently flame resistant fibers on thefront face of the fabric to impart the requisite thermal and arcprotection and predominantly locating the more comfortable (and lessexpensive) fibers on the back face of the fabric positioned next to thewearer. In this way, overall protection of the fabric is maintainedwhile improving comfort. Some embodiments of such fabrics may alsoachieve NFPA 70E PPE Category 2 protection (8 cal/cm² arc rating whetherATPV or EBT). Moreover, in some embodiments the flame resistant fabricscontain fibers having at least one energy absorbing and/or reflectingadditive incorporated into the fibers. Inclusion of such fibers into thefabric increases the arc protection of the fabric while still complyingwith all requisite thermal protective requirements.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

Some embodiments of the fabrics described herein have anisotropicproperties in that the fabrics are constructed such that the body sideof the fabric (the side of the fabric proximate the wearer (assuming thefabric will be incorporated into a garment)) and the face side of thefabric (the side of the fabric facing away from the wearer) havedifferent properties. More specifically, in some embodiments a higherpercentage of inherently flame resistant fibers (or yarns containing thefibers) are located and exposed on the face side of the fabric (asopposed to on the body side of the fabric). In such embodiments, ahigher percentage of less expensive and more comfortable fibers (oryarns containing the fibers) are located and exposed on the body side ofthe fabric (as opposed to on the face side of the fabric). In suchembodiments, the face side of the fabric thus effectively imparts therequisite thermal and arc protection and the body side of the fabricprovides superior comfort and/or lower cost in relation to the face sideof the fabric.

Fabrics according to such embodiments can be formed pursuant to anymethod that results in the fabric having different properties on thebody side and the face side of the fabric. In some embodiments, thefabrics are a woven, knitted, and/or nonwoven fabric.

Woven and/or knitted fabrics may be formed to have anisotropicproperties through the use of at least a first group of yarns and asecond group of yarns, whereby each yarn group has a different fiberblend. The different fiber blends can be attributable to the two yarngroups having different amounts of the same fibers or to the two yarngroups having different fibers or different blends of fibers. Inaddition, it will be recognized that in some embodiments the yarns neednot be blended at all. In other words, some yarns could be 100% of asingle fiber type. Regardless, the first group of yarns is predominantlyexposed on the face side of the fabric and the second group of yarns ispredominantly exposed on the body side of the fabric. In someembodiments, the fabric is formed only of the first group of yarns andthe second group of yarns (i.e., these two yarn types form the entiretyof the fabric). In other embodiments, yarns in addition to the first andsecond groups of yarns may be incorporated into the fabric.

Fabrics of the invention may be formed with spun yarns, filament yarns,stretch broken yarns, or combinations thereof. The yarns can comprise asingle yarn or two or more individual yarns that are combined togetherin some form, including, but not limited to, twisting, plying, tacking,wrapping, covering, core-spinning (i.e., a filament or spun core atleast partially surrounded by spun fibers or yarns), etc.

In some embodiments, the yarns of the first group of yarns (“firstyarns”) are spun yarns having a fiber blend that includes inherentlyflame resistant fibers. In some embodiments, the first yarns include atleast 50% inherently flame resistant fibers, at least 55% inherentlyflame resistant fibers, at least 60% inherently flame resistant fibers,at least 65% inherently flame resistant fibers, at least 70% inherentlyflame resistant fibers, at least 75% inherently flame resistant fibers,at least 80% inherently flame resistant fibers, at least 85% inherentlyflame resistant fibers, and/or at least 90% inherently flame resistantfibers. Examples of suitable inherently flame resistant fibers include,but are not limited to, para-aramid fibers, meta-aramid fibers,polybenzoxazole (“PBO”) fibers, polybenzimidazole (“PBI”) fibers,modacrylic fibers, poly{2,6-diimidazo[4,5-b:40;50-e]-pyridinylene-1,4(2,5-dihydroxy)phenylene} (“PIPD”) fibers,polyacrylonitrile (PAN) fibers, liquid crystal polymer fibers, glassfibers, carbon fibers, TANLON™ fibers (available from Shanghai TanlonFiber Company), wool fibers, melamine fibers (such as BASOFIL™,available from Basofil Fibers), polyetherimide fibers, pre-oxidizedacrylic fibers, polyamide-imide fibers such as KERMEL™,polytetrafluoroethylene fibers, polyetherimide fibers, polyimide fibers,and polyimide-amide fibers and any combination or blend thereof.Examples of para-aramid fibers include KEVLAR™ (available from DuPont),TECHNORA™ (available from Teijin Twaron BV of Arnheim, Netherlands), andTWARON™ (also available from Teijin Twaron By), and Taekwang para-aramid(available from Taekwang Industries). Examples of meta-aramid fibersinclude NOMEX™ (available from DuPont), CONEX™ (available from Teijin),APYEIL™ (available from Unitika), ARAWIN (available from Toray). Anexample of suitable modacrylic fibers are PROTEX™ fibers available fromKaneka Corporation of Osaka, Japan, SEF™ available from Solutia, orblends thereof.

The same inherently flame resistant fibers may be used in the firstyarns, but such is not a requirement. Rather, the fiber blend of thefirst yarns may include the same type of inherently flame resistantfibers or, alternatively, different types of inherently flame resistantfibers may be provided in the blend.

In some embodiments, the inherently flame resistant fibers in the firstyarns include a blend of aramid fibers (meta-aramid, para-aramid, orboth) and modacrylic fibers. The modacrylic fibers are significantlyless expensive than the aramid fibers, thus helping to contain the costof the fabric. Moreover, in some embodiments the percentage ofmodacrylic fibers in the fiber blend of the first yarns is up to 2times, up to 3 times, up to 4 times, up to 5 times, up to 6 times, up to7 times, and/or up to 8 times the percentage of aramid fibers in theblend. In some embodiments, the first yarns include at least 40%modacrylic fibers, at least 45% modacrylic fibers, at least 50%modacrylic fibers, at least 55% modacrylic fibers, at least 60%modacrylic fibers, at least 65% modacrylic fibers, at least 70%modacrylic fibers, at least 75% modacrylic fibers, and/or at least 80%modacrylic fibers. In some embodiments, the first yarns includeapproximately (i) 40-90% modacrylic fibers, inclusive; (ii) 45-85%modacrylic fibers, inclusive; (iii) 50-80% modacrylic fibers, inclusive;(iv) 50-70% modacrylic fibers, inclusive; (v) 55-65% modacrylic fibers,inclusive; (vi) 60-80% modacrylic fibers, inclusive; and/or (vii) 65-75%modacrylic fibers, inclusive. In some embodiments, the first yarnsinclude at least 5% aramid fibers, at least 10% aramid fibers, at least15% aramid fibers, at least 20% aramid fibers, at least 25% aramidfibers, at least 30% aramid fibers, and/or at least 35% aramid fibers.In some embodiments, the first yarns include approximately (i) 5-35%aramid fibers, inclusive; (ii) 10-30% aramid fibers, inclusive; (iii)15-25% aramid fibers, inclusive; (iv) 10-20% aramid fibers, inclusive;(v) 10-15% aramid fibers, inclusive; and/or (vi) 15-20% aramid fibers,inclusive.

In some embodiments, the first yarns include approximately (i) 5-35%aramid fibers and 40-90% modacrylic fibers, inclusive; (ii) 5-25% aramidfibers and 50-80% modacrylic fibers, inclusive; (iii) 10-20% aramidfibers and 50-80% modacrylic fibers, inclusive; (iv) 10-20% aramidfibers and 50-70% modacrylic fibers, inclusive; (v) 10-20% aramid fibersand 50-60% modacrylic fibers, inclusive; (vi) 15-25% aramid fibers and60-80% modacrylic fibers, inclusive; (vii) 15-25% aramid fibers and65-75% modacrylic fibers, inclusive; (viii) 18-23% aramid fibers and65-75% modacrylic fibers, inclusive; (ix) 10-15% aramid fibers and50-65% modacrylic fibers, inclusive; and/or (x) 10-15% aramid fibers and50-60% modacrylic fibers, inclusive.

In some embodiments, cellulosic fibers may be added to the fiber blendof the first yarns to reduce cost and impart comfort. In someembodiments, the first yarns include at least 5% cellulosic fibers, atleast 10% cellulosic fibers, at least 15% cellulosic fibers, at least20% cellulosic fibers, at least 25% cellulosic fibers, at least 30%cellulosic fibers, at least 35% cellulosic fibers, at least 40%cellulosic fibers, at least 45% cellulosic fibers, or at least 50%cellulosic fibers. In some embodiments, the first yarns includeapproximately (i) 5-50% cellulosic fibers, inclusive; (ii) 10-35%cellulosic fibers, inclusive; (iii) 5-25% cellulosic fibers, inclusive;(iv) 5-20% cellulosic fibers, inclusive; (v) 5-15% cellulosic fibers,inclusive; (vi) 10-20% cellulosic fibers, inclusive; (vii) 10-15%cellulosic fibers, inclusive; (viii) 20-40% cellulosic fibers,inclusive; and/or (ix) 25-35% cellulosic fibers, inclusive.

In some embodiments, the cellulosic fibers are lyocell fibers and/ornon-FR lyocell fibers. In some embodiments, blends of differentcellulosic fibers are used in the fiber blend of the first yarns. Whilethe cellulosic fibers can be treated so as to be flame resistant, thisis not necessary. Rather, inclusion of the inherently flame resistantfibers in the fiber blend imparts sufficient flame resistance and arcprotection and prevents the cellulosic fibers from burning. For example,the modacrylic fibers control and counteract the flammability of thecellulosic fibers to prevent the cellulosic fibers from burning. In thisway, the cellulosic fibers (or the yarns or fabrics made with suchfibers) need not be treated with a FR compound or additive.

In some embodiments, the first yarns include approximately (i) 5-35%aramid fibers, 40-90% modacrylic fibers, and 5-50% cellulosic fibers (FRand/or non-FR), inclusive; (ii) 5-30% aramid fibers, 50-80% modacrylicfibers, and 10-40% cellulosic fibers (FR and/or non-FR), inclusive;(iii) 5-25% aramid fibers, 50-80% modacrylic fibers, and 15-40%cellulosic fibers (FR and/or non-FR), inclusive; (iv) 10-20% aramidfibers, 50-70% modacrylic fibers, and 20-45% cellulosic fibers (FRand/or non-FR), inclusive; (v) 10-20% aramid fibers, 50-70% modacrylicfibers, and 20-40% cellulosic fibers (FR and/or non-FR), inclusive; (vi)10-15% aramid fibers, 55-70% modacrylic fibers, and 25-40% cellulosicfibers (FR and/or non-FR), inclusive; (vii) 10-30% aramid fibers, 60-80%modacrylic fibers, and 5-20% cellulosic fibers (FR and/or non-FR),inclusive; and/or (viii) 15-25% aramid fibers, 65-75% modacrylic fibers,and 5-15% cellulosic fibers (FR and/or non-FR), inclusive.

In some embodiments, the yarns of the second group of yarns (“secondyarns”) are spun yarns having a fiber blend that includes more fibersthat are more comfortable and less expensive than fibers in the firstyarns. Such fibers include, but are not limited to, natural andsynthetic cellulosic fibers (e.g., cotton, rayon, acetate, triacetate,and lyocell, as well as their flame resistant counterparts FR cotton, FRrayon, FR acetate, FR triacetate, and FR lyocell), modacrylic fibers,wool, TANLON™ fibers (available from Shanghai Tanlon Fiber Company),nylon fibers, polyester fibers, etc., and blends thereof. An example ofFR rayon fibers is Lenzing FR™ fibers, also available from LenzingFibers Corporation, and VISIL™ fibers, available from Sateri. Examplesof lyocell fibers include TENCEL™, TENCEL G100™ and TENCEL A100™ fibers,all available from Lenzing Fibers Corporation. An example of a polyesterfiber is DACRON® fibers (available from Invista™). Examples of suitablemodacrylic fibers are PROTEX™ fibers available from Kaneka Corporationof Osaka, Japan, SEF™ fibers available from Solutia, PyroTex® fibersavailable from PyroTex Fibers GmbH, or blends thereof.

The second yarns preferably include cellulosic fibers for comfort, whichcan be FR and/or non-FR. In some embodiments, the cellulosic fibers arelyocell fibers and/or non-FR lyocell fibers. In some embodiments, thesecond yarns include at least 10% cellulosic fibers, at least 20%cellulosic fibers, at least 30% cellulosic fibers, at least 40%cellulosic fibers, at least 50% cellulosic fibers, at least 60%cellulosic fibers, at least 70% cellulosic fibers, at least 80%cellulosic fibers, or at least 90% cellulosic fibers. In someembodiments, the second yarns include approximately (i) 50-90%cellulosic fibers, inclusive; (ii) 55-85% cellulosic fibers, inclusive;(iii) 60-85% cellulosic fibers, inclusive; (iv) 65-85% cellulosicfibers, inclusive; (v) 70-85% cellulosic fibers, inclusive; (vi) 70-80%cellulosic fibers, inclusive; (vii) 60-75% cellulosic fibers, inclusive;and/or (viii) 65-75% cellulosic fibers, inclusive.

In some embodiments, the second yarns include a blend of cellulosicfibers and inherently flame resistant fibers (such as aramid fibers),which enhance thermal and arc protection and which help to resistthermal shrinkage. If inherently flame resistant fibers are included inthe fiber blend of the second yarns, the percentage of such fibers arepreferably (but do not have to be) less than the percentage ofinherently flame resistant fibers used in the fiber blend of the firstyarns. In some embodiments, inherently flame resistant fibers constitute50% or less, 40% or less, 30% or less, or 20% or less of the fiber blendof the second yarns. In some embodiments, the second yarns include atleast 10% inherently flame resistant fibers, at least 15% inherentlyflame resistant fibers, at least 20% inherently flame resistant fibers,at least 25% inherently flame resistant fibers, at least 30% inherentlyflame resistant fibers, at least 35% inherently flame resistant fibers,and/or at least 40% inherently flame resistant fibers. In someembodiments, the second yarns include approximately (i) 10-50%inherently flame resistant fibers, inclusive; (ii) 10-40% inherentlyflame resistant fibers, inclusive; (iii) 10-35% inherently flameresistant fibers, inclusive; (iv) 10-30% inherently flame resistantfibers, inclusive; (v) 15-25% inherently flame resistant fibers,inclusive; and/or (vi) 20-30% inherently flame resistant fibers,inclusive.

In some embodiments, the second group of yarns includes approximately(i) 50-90% cellulosic fibers and 10-50% inherently flame resistantfibers, inclusive; (ii) 60-90% cellulosic fibers and 10-40% inherentlyflame resistant fibers, inclusive; (iii) 65-85% cellulosic fibers and10-35% inherently flame resistant fibers, inclusive; (iv) 65-80%cellulosic fibers and 10-30% inherently flame resistant fibers,inclusive; (v) 70-80% cellulosic fibers and 20-30% inherently flameresistant fibers, inclusive; and/or (vi) 65-75% cellulosic fibers and15-25% inherently flame resistant fibers, inclusive.

In some embodiments, different cellulosic fibers (e.g., blends oflyocell and rayon, blends of FR and non-FR cellulosic fibers, etc.)and/or inherently flame resistant fibers (e.g., para-aramid,meta-aramid, and/or modacrylic, etc.) are used in the fiber blend of thesecond yarns. In some embodiments, the inherently flame resistant fibersused in the fiber blend of the second yarns are modacrylic fibers and/oraramid fibers, such as para-aramid fibers, meta-aramid fibers, or blendsthereof. In some embodiments, the modacrylic fibers constitute a greaterpercentage of the fiber blend of the second yarns than the aramidfibers. In some embodiments, the modacrylic fibers constitute 0-30% andthe aramid fibers constitute 1-30% of the fiber blend of the secondyarns. In some embodiments, the modacrylic fibers constitute 0-25% andthe aramid fibers constitute 1-25% of the fiber blend of the secondyarns. In some embodiments, the modacrylic fibers constitute 5-20% andthe aramid fibers constitute 1-15% of the fiber blend of the secondyarns. In some embodiments, the modacrylic fibers constitute 10-20% andthe aramid fibers constitute 1-5% of the fiber blend of the secondyarns. In some embodiments, the modacrylic fibers constitute 15-20% andthe aramid fibers constitute 1-5% of the fiber blend of the secondyarns.

In some embodiments, the second yarns include approximately (i) 1-20%aramid fibers, 5-40% modacrylic fibers, and 50-90% cellulosic fibers (FRand/or non-FR), inclusive; (ii) 1-15% aramid fibers, 10-35% modacrylicfibers, and 65-90% cellulosic fibers (FR and/or non-FR), inclusive;(iii) 1-10% aramid fibers, 10-25% modacrylic fibers, and 70-90%cellulosic fibers (FR and/or non-FR), inclusive; (iv) 1-5% aramidfibers, 10-20% modacrylic fibers, and 75-85% cellulosic fibers (FRand/or non-FR), inclusive; and/or (v) 1-5% aramid fibers, 15-20%modacrylic fibers, and 75-85% cellulosic fibers (FR and/or non-FR),inclusive.

In some embodiments, the fiber blend of the second yarns is devoid ofmodacrylic fibers. In some embodiments, aramid fibers are the onlyinherently flame resistant fibers provided in the second yarns. In suchembodiments, the second yarns can include approximately (i) 5-50% aramidfibers, inclusive; (ii) 10-45% aramid fibers, inclusive; (iii) 10-40%aramid fibers, inclusive; (iv) 15-35% aramid fibers, inclusive; (v)20-35% aramid fibers, inclusive; and/or (vi) 25-35% aramid fibers,inclusive. In such embodiments, the second yarns include approximately(i) 50-90% cellulosic fibers and 10-50% aramid fibers, inclusive; (ii)60-80% cellulosic fibers and 20-40% aramid fibers, inclusive; (iii)65-80% cellulosic fibers and 25-35% aramid fibers, inclusive; and/or(iv) 65-75% cellulosic fibers and 25-35% aramid fibers, inclusive.

In some embodiments, the fiber blend of the overall fabric includesapproximately (i) 25-65% cellulosic fibers (e.g., lyocell fibers and/ornon-FR lyocell fibers), 25-65% modacrylic fibers, and 5-25% aramidfibers, inclusive; (ii) 30-60% cellulosic fibers (e.g., lyocell fibersand/or non-FR lyocell fibers), 25-60% modacrylic fibers, and 5-20%aramid fibers, inclusive; (iii) 35-60% cellulosic fibers (e.g., lyocellfibers and/or non-FR lyocell fibers), 30-55% modacrylic fibers, and5-15% aramid fibers, inclusive; (iv) 40-60% cellulosic fibers (e.g.,lyocell fibers and/or non-FR lyocell fibers), 30-50% modacrylic fibers,and 5-15% aramid fibers, inclusive; (v) 40-55% cellulosic fibers (e.g.,lyocell fibers and/or non-FR lyocell fibers), 30-50% modacrylic fibers,and 5-15% aramid fibers, inclusive; (vi) 45-55% cellulosic fibers (e.g.,lyocell fibers and/or non-FR lyocell fibers), 35-45% modacrylic fibers,and 5-15% aramid fibers, inclusive; (vii) 25-50% cellulosic fibers(e.g., lyocell fibers and/or non-FR lyocell fibers), 25-50% modacrylicfibers, and 10-40% aramid fibers, inclusive; (viii) 30-45% cellulosicfibers (e.g., lyocell fibers and/or non-FR lyocell fibers), 30-45%modacrylic fibers, and 15-30% aramid fibers, inclusive; and/or (ix)30-40% cellulosic fibers (e.g., lyocell fibers and/or non-FR lyocellfibers), 35-45% modacrylic fibers, and 20-30% aramid fibers, inclusive.

It may be beneficial, but not required, to include nylon fibers ineither or both of the first yarns and the second yarns as nylon fibersimpart abrasion resistance and thus enhance the durability and wearproperties of the fabric made with such yarns.

It has also been discovered that incorporating into the fabric (via thefirst yarns, second yarns, or otherwise) fibers having at least oneenergy absorbing and/or reflecting additive increases the arc rating ofthe fabric while still complying with all requisite thermal protectiverequirements.

It is believed that such energy (e.g., radiation) absorbing and/orreflecting additives serve to prevent heat energy transmission throughthe fabric and to the wearer's skin by absorbing the energy and/orreflecting the energy away from the fabric such that it does not reachthe wearer. Additive-containing fibers (“AC fibers”) are fibers wherebyan energy absorbing and/or reflecting additive is introduced during theprocess of manufacturing the fibers themselves and not after fiberformation. This is in contrast to a finish applied onto the fabricsurface whereby a binder typically must be used to fix the additive ontothe fabric. In these cases, the additive is apt to wash and/orwear/abrade off the fabric during laundering. Provision of the additivein the fibers during fiber formation results in better durability as theadditive is trapped within the fiber structure. Examples of AC fibersare identified and described in U.S. Patent Publication No. 2017/0370032to Stanhope et al., U.S. Patent Publication No. 2017/0295875 to Ohzekiet al., and U.S. patent Ser. No. 16/271,162 to Stanhope et al., theentirety of each of which is herein incorporated by reference. Note thatwhile AC fibers may be used in embodiments of the fabrics contemplatedherein, they need not always be used. For example, some AC fibers areproducer-colored fibers. In producer coloring (also known as “solutiondyeing”), pigment is injected into the polymer solution prior to formingthe fibers. Thus, “producer-colored” fibers refers to fibers that arecolored during the process of manufacturing the fibers themselves andnot after fiber formation. If darker-colored additives (such as navy andblack) are used to color the fibers, use of such darker fibers (such asproducer-colored aramid fibers) in fabrics may render the fabrics moredifficult to dye to lighter shades of color. Thus, it might not alwaysbe desirable to use AC aramid fibers in the blends disclosed herein,particularly if such AC aramid fibers are darker shades.

If AC fibers are desired, the AC fibers may be incorporated into eitheror both of the first and second yarns. In some embodiments, the ACfibers are incorporated into the first yarns so as to be exposed on theface side of the fabric. For example, in some embodiments the AC fibersare modacrylic fibers that include an infrared absorber, such asdescribed in U.S. Patent Publication No. 2017/0295875 to Ohzeki et al.and/or sold as PROTEX™ A fibers by Kaneka Corporation of Osaka, Japan(as opposed to PROTEX™ C fibers which do not contain such an additive).

In some embodiments, the AC fibers are incorporated into the fiber blendof the first yarns to enhance the arc protection on the face of thefabric. In some embodiments, the AC fibers are only incorporated intothe fiber blend of the first yarns and are not incorporated into thesecond yarns. In some embodiments, the modacrylic fibers in the firstyarns are AC fibers, such as, but not limited to, PROTEX™ A fibers.

The AC fibers provided in the fabric need not all be the same. Forexample, the fiber blend may include the same type of AC fiber or,alternatively, different types of AC fibers may be provided in theblend.

In some embodiments, the AC fibers (such as the AC version of any of thefibers identified above) constitute 20-60%, inclusive, of the fiberblend of the fabric; 20-50%, inclusive, of the fiber blend of thefabric; 25-50%, inclusive, of the fiber blend of the fabric; 25-45%,inclusive, of the fiber blend of the fabric; 30-45%, inclusive, of thefiber blend of the fabric; or 35-45%, inclusive, of the fiber blend ofthe fabric. In some embodiments, the AC fibers constitute at least 5% orat least 10% or at least 15% or at least 20% or at least 25% or at least30% or at least 35% or at least 40% or at least 45% and (i) no more than60%, (ii) no more than 50%, (iii) no more than 45%, (iv) no more than40%, or (v) no more than 35%, inclusive, of the fiber blend of thefabric.

In some embodiments, the fabrics are woven fabrics formed of the firstyarns and the second yarns. In some embodiments, only the first yarnswill be oriented in the warp direction and only the second yarns will beoriented in the fill direction. In this way, the fibers on the face sideof the fabric will predominantly comprise those of the first yarns andthe fibers on the body side of the fabric will predominantly comprisethose of the second yarns.

In other embodiments, not all of the warp or fill yarns are the same.For example, the first and second yarns may be provided in both the warpand fill directions by providing the first yarns on some ends and picksand the second yarns on other ends and picks (in any sort of randomarrangement or alternating pattern). Or all of the yarns in one of thewarp or fill direction could be identical (e.g., either all first yarnsor all second yarns) and different yarns (both first and second yarns)used only in the other of the warp or fill direction.

The fabric may be constructed with the first and second yarns in avariety of ways, including but not limited to, one or more of twillweave (2×1, 3×1, etc.), twill weave containing a rip-stop pattern, satinweave (4×1, 5×1, etc.), sateen weave, and double-cloth constructions, orany other weave where yarn is predominantly more on one side of thefabric than the other side of the fabric. A person skilled in the artwould be familiar with and could utilize suitable fabric constructions.

It will also be recognized that any woven fabric will have both warp andfill yarns visible on each side of the fabric. Fabrics woven inaccordance with some embodiments of the present invention, however, arewoven such that more of the first yarns are located on the face side ofthe fabric, and thus more of the second yarns are located on the bodyside of the fabric. Thus, in an exemplary fabric construction in whichmore of the first yarns are located or exposed on the face side of thefabric and more of the second yarns are located or exposed on the bodyside of the fabric, the first yarns are “predominantly” exposed on theface side of the fabric (even though some of the first yarns would bevisible from the body side of the fabric) and the second yarns are“predominantly” exposed on the body side of the fabric (even though someof the second yarns would be visible from the face side of the fabric).

In other embodiments of the invention, a knit fabric that has differentproperties on each side of the fabric can be constructed. Such a fabriccould be constructed using double-knit technology such that the firstyarns will be predominantly exposed on the face side of the fabric andthe second yarns will be predominantly exposed on the opposing body sideof the fabric.

Embodiments of the fabric can be of any weight, but in some embodimentsare between 5 to 7 ounces per square yard (osy), inclusive. In someembodiments, the fabric weight is at least 5 osy but less than or equalto 7 osy, 6.9 osy, 6.8 osy, 6.7 osy, 6.6 osy, 6.5 osy, 6.4 osy, 6.3 osy,6.2 osy, 6.1 osy, 6.0 osy, 5.9 osy, 5.8 osy, 5.7 osy, 5.6 osy, 5.5 osy,5.4 osy, 5.3 osy, 5.2 osy, and/or 5.1 osy.

Fabrics according to some embodiments of the present inventionstrategically place fibers useful for thermal and arc protection (e.g.,aramid fibers which tend to be more expensive and less comfortable) onthe face side of the fabric and more comfortable, less expensive fiberson the body side of the fabric. These fabrics thus provide the requisiteprotection to the wearer while rendering the garment more comfortableand affordable as compared to existing fabrics. The cost of the fabricsis contained due to (among other things): (1) incorporation ofcellulosic fibers in the first yarns and inclusion of large amounts ofcellulosic fibers in the second yarns; (2) limiting the amount ofinherently FR fibers (more expensive fibers such as aramid fibers) inthe fabric but concentrating those fibers on the face of the fabric; (3)inclusion of inherently FR fibers, which permits lower weight (and thusless expensive) fabrics to perform as required; (4) use of moremodacrylic fibers than aramid fibers, which are significantly lessexpensive while still imparting thermal and arc protection to thefabric; and/or (5) use of AC fibers in the first yarns so as to bepredominantly exposed on the face side of the fabric where the AC fibersare more effective for improving ATPV than if they were exposed on thebody side of the fabric.

Table 1 sets forth testing results of various properties of someembodiments of the inventive fabrics contemplated herein (Fabrics 1-5).Fabrics 1-5 were finished but without the use of any property-imparting(e.g., flame retardant) additive.

TABLE 1 Property Fabric 1 Fabric 2 Fabric 3 Fabric 4 Fabric 5 First YarnBlend 55 Protex 55 Protex 60 Protex 60 Protex 70 Protex A/35 A/30 A/25A/28 A/10 Tencel/ Tencel/ Tencel/ Tencel/ Tencel/ 5 Meta/ 10 Meta/ 10Meta/ 7 Meta/ 10 Meta/ 5 Para 5 Para 5 Para 5 Para 10 Para Second YarnBlend 80 Tencel/ 80 Tencel/ 80 Tencel/ 80 Tencel/ 70 Tencel/ NFPA 70E/NFPA 2112 17 Protex 17 Protex 17 Protex 17 Protex 25 Meta/ ASTM 1506Requirement C/3 Para C/3 Para C/3 Para C/3 Para 5 Para Requirement Weave2 × 1 RHT 2 × 1 RHT 2 × 1 RHT 2 × 1 RHT 2 × 1 RHT Width Overall (in)61.8 62.2375 61.075 62.25 62.275 Width Inside Pins 60.98 61.06 60.4861.28 61.36 (in) Weight (osy) 6 5.9 5.9 5.8 5.7 Construction 64 × 52 64× 50 65 × 50 65 × 50 76 × 56 (w × f) Vertical Flammability - Before WashAfter Flame (sec) 0 × 0 0 × 0 0 × 0 0 × 0 0 × 0 <2 × 2  <2 × 2 CharLength (inch) 3.4 × 2.9 3.5 × 2.5 3.6 × 2.5 3.6 × 2.9 2.0 × 2.9 <6 × 6 <4 × 4 After Glow (sec) 3 × 3 2 × 2 2 × 2 2 × 2 2 × 2 VerticalFlammability - After 100x IL* After Flame (sec) 0 × 0 0 × 0 0 × 0 0 × 00 × 0 <2 × 2 Char Length (inch) 3.4 × 3.4 3.5 × 2.2 3.9 × 2.2 3.3 × 2.62.0 × 3.3 <4 × 4 After Glow (sec) 8 × 7 7 × 6 7 × 7 7 × 7 5 × 6 TensileStrength 99 × 93 107 × 79  114 × 96  112 × 91  110 × 95  30 × 30 (lbf)Elmendorf Tear 9.8 × 10  11.5 × 10.4 12.0 × 10.2 10.8 × 10.5 8.6 × 7.72.5 × 2.5 (lbf) Laundry Shrinkage −5.3 × −6.5 −4.0 × −6.4 −4.2 × −5.4−4.2 × −6.5 −3.0 × −1.8 (%) - After 5x PP120** Thermal Shrinkage (%)Before Wash −8.4 × −4.3 −7.1 × −4.8 −8.1 × −5.3 −8.3 × −5.5 −7.1 × −2.6<10 × 10 After 3x IL −8.2 × −5.3 −6.1 × −5.2 −7.5 × −5.1 −7.4 × −5.2−5.4 × −3.0 <10 × 10 Air permeability 144 161 142 154 99 (cfm/ft²) HTP-Before Wash (cal/cm²) with Spacer 10.3 10.2 10.3 10.3 9.8 >6 w/o Spacer7.3 7.3 7.1 7.2 6.8 >3 HTP- After 3x IL (cal/cm²) with Spacer 12.3 1211.4 11.8 11 >6 w/o Spacer 8.7 8.1 8.2 8.6 7.6 >3 Wicking Droplet Test(s) Before Wash 0.5 0.5 0.4 0.4 0.7 After 5x PP120 0.8 0.9 0.9 1 2.5 ArcRating 8 8.6 8.1 8.3 8.5 (cal/cm²) *The fabrics were laundered inaccordance with the industrial laundering (“IL”) specifications setforth in NFPA 2112. **The fabrics were laundered in accordance withAATCC Method 135, 3, IV, A iii (Dimensional Changes of Fabrics afterHome Laundering, 2018 edition, incorporated herein by reference). Morespecifically, the fabrics were laundered via permanent press at 120° F.(“PP120”).

Vertical flammability (char length, after flame, and after glow) weretested in accordance with AS™ D6413: Standard Test Method for FlameResistance of Textiles (Vertical Test) (2015 edition). Tensile strengthwas tested in accordance with D5034: Standard Test Method for BreakingStrength and Elongation of Textile Fabrics (Grab Test) (2009 edition),and the results are represented in pounds force (“lbf”). Elmendorf tearstrength was tested in accordance with AS™ D1424: Standard Test Methodfor Tearing Strength of Fabrics by Falling-Pendulum (Elmendorf-Type)Apparatus (2009 edition), and the results are represented in poundsforce (“lbf”). Laundry shrinkage was tested in accordance with AATCCMethod 135, 3, IV, A iii: Dimensional Changes of Fabrics after HomeLaundering (2018 edition). Thermal shrinkage was tested in accordancewith NFPA 2112. Heat transfer performance/radiant heat resistance(“HTP”) was tested in accordance with ASTM F1939: Standard Test Methodfor Radiant Heat Resistance of Flame Resistant Clothing Materials withContinuous Heating (2015 edition), and the results are reported incalories per centimeter². All of these testing methodologies areincorporated herein by reference.

Embodiments of the fabrics disclosed herein comply with the verticalflammability requirements of both AS™ F1506 (char length of 6 inches orless and a two second or less afterflame) and NFPA 2112 (char length of4 inches or less and a two second or less afterflame), when measuredpursuant to the testing methodology set forth in AS™ D6413, as well asthe thermal shrinkage requirement (no more than 10% thermal shrinkage)of NFPA 2112.

Moreover, many of the inventive fabrics achieved an arc rating (ATPV orEBT) greater or equal to 8 cal/cm² so as to have a PPE Category 2 ratingunder NFPA 70E even at low weights (e.g., between 5-7 osy, inclusive).Embodiments of the fabrics disclosed herein achieve surprisingly higharc rating/fabric weight ratios. In some embodiments, the arcrating/fabric weight ratio is 1.1-1.6, inclusive; 1.2-1.6, inclusive;1.3-1.6, inclusive; 1.4-1.6, inclusive; and 1.4-1.5, inclusive. In someembodiments, the arc rating/fabric weight ratio is at least 1.2; atleast 1.25; at least 1.3; at least 1.35; at least 1.4; at least 1.45; atleast 1.5; at least 1.55; and/or at least 1.6. Even higher arcrating/fabric weight ratios may be achieved by increasing the amount ofAC fibers (FR or non-FR) in the blend.

Incorporation of cellulosic and modacrylic fibers in the fiber blendsimpart excellent moisture management properties to the fabric whentested pursuant to AATCC 79: Absorbency of Textiles (2018 edition,incorporated herein by reference). In other words, the fabrics are ableto quickly draw moisture away from the wearer's body via capillaryaction. Under AATCC 79, a droplet of water is deposited on the fabricsurface, and the time it takes for the droplet to absorb fully into thefabric is measured. Some embodiments of the fabrics contemplated hereinachieve an absorbency time of 5 seconds or less when tested pursuant toAATCC 79, as evidenced in Tables 1-4 (see “Wicking Droplet Test”). Suchtesting is to be performed on unfinished fabrics as the wicking propertyof a fabric can be easily manipulated with the use of finishes.

In addition to wicking ability, the air permeability of the fabric isalso relevant to the comfort of the fabric. The air permeability of afabric is determined by test method AS™ D737: Standard Test Method forAir Permeability of Textile Fabrics (2018 edition, incorporated hereinby reference) and gauges how easily air passes through a fabric. Thefabric is placed on a device that blows air through the fabric, and thedevice measures the volume flow of air through the fabric at aparticular pressure (reported as “f³/min/ft²” or cubic foot per minuteper square foot). Higher air permeability values mean that the fabric ismore breathable, which is typically desirable. Embodiments of the fabriccontemplated herein have good air permeability (in the range of 80-250f³/min/ft², inclusive; 90-200 f³/min/ft², inclusive; 100-150 f³/min/ft²,inclusive) when tested pursuant to AS™ D737.

The fabrics described herein can be incorporated into any type of singleor multi-layer garment (uniforms, shirts, jackets, trousers andcoveralls) where protection against electric arc flash and/or flames isneeded and/or desirable.

EXAMPLES

A collection of exemplary embodiments, including at least someexplicitly enumerated as “Examples” providing additional description ofa variety of example types in accordance with the concepts describedherein are provided below. These examples are not meant to be mutuallyexclusive, exhaustive, or restrictive; and the invention is not limitedto these example examples but rather encompasses all possiblemodifications and variations within the scope of the issued claims andtheir equivalents.

Example 1. A fabric formed by first yarns and a second yarns, whereinthe fabric has a first side and a second side opposite the first sideand wherein: the first yarns comprise a first fiber blend comprisingaramid fibers, modacrylic fibers, and cellulosic fibers; the aramidfibers and the modacrylic fibers of the first fiber blend constitute atleast 50% of the first fiber blend; the first fiber blend comprises moremodacrylic fibers than aramid fibers; the second yarns comprises asecond fiber blend that is different from the first fiber blend and thatcomprises aramid fibers, modacrylic fibers, and cellulosic fibers; thesecond fiber blend comprises at least 60% cellulosic fibers; the secondfiber blend comprises more modacrylic fibers than aramid fibers; thefirst yarns are predominantly exposed on the first side of the fabric;the second yarns are predominantly exposed on the second side of thefabric; the fabric has a char length of at least 6 inches and anafterflame of 2 seconds or less when tested pursuant to AS™ D6413(2015); the fabric has a fabric weight between 5 to 7 ounces per squareyard, inclusive; and the fabric has an arc rating of at least 8 cal/cm²when tested pursuant to AS™ F1959 (2014).

Example 2. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the aramid fibers and the modacrylicfibers of the first fiber blend constitute at least 60% of the firstfiber blend.

Example 3. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the first fiber blend comprises up to 2times more modacrylic fibers than aramid fibers.

Example 4. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the first fiber blend comprises up to 3times more modacrylic fibers than aramid fibers.

Example 5. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the first fiber blend comprisesapproximately 5-25% aramid fibers, 50-80% modacrylic fibers, and 15-40%cellulosic fibers.

Example 6. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the cellulosic fibers in the firstfiber blend are non-FR lyocell fibers.

Example 7. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the modacrylic fibers in the firstfiber blend are additive-containing fibers.

Example 8. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the aramid fibers in the first fiberblend comprise meta-aramid fibers and para-aramid fibers.

Example 9. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the second fiber blend comprises atleast 70% cellulosic fibers.

Example 10. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the modacrylic fibers and aramid fibersof the second fiber blend constitute 40% or less of the second fiberblend.

Example 11. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the fabric is a woven fabric comprisinga first fabric direction and a second fabric direction opposite thefirst fabric direction, wherein the first yarns are provided only in thefirst fabric direction and the second yarns are provided only in thesecond fabric direction.

Example 12. A garment formed with the fabric of any of the preceding orsubsequent examples or combination of examples, the garment having aface side and a body side, wherein the first side of the fabric isexposed on the face side of the garment and the second side of thefabric is exposed on the body side of the garment.

Example 13. A fabric formed by first yarns and a second yarns, whereinthe fabric has a first side and a second side opposite the first sideand wherein: the first yarns comprise a first fiber blend comprisingaramid fibers, modacrylic fibers, and cellulosic fibers; the aramidfibers and the modacrylic fibers of the first fiber blend constitute atleast 70% of the first fiber blend; the first fiber blend comprises moremodacrylic fibers than aramid fibers; the second yarns comprises asecond fiber blend that is different from the first fiber blend and thatcomprises aramid fibers and non-FR cellulosic fibers; the second fiberblend is devoid of modacrylic fibers; the second fiber blend comprisesat least 50% non-FR cellulosic fibers; the first yarns are predominantlyexposed on the first side of the fabric; the second yarns arepredominantly exposed on the second side of the fabric; the fabric has achar length of at least 6 inches and an afterflame of 2 seconds or lesswhen tested pursuant to AS™ D6413 (2015); the fabric has a fabric weightbetween 5 to 7 ounces per square yard, inclusive; and the fabric has anarc rating of at least 8 cal/cm² when tested pursuant to AS™ F1959(2014).

Example 14. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the aramid fibers and the modacrylicfibers of the first fiber blend constitute at least 80% of the firstfiber blend.

Example 15. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the first fiber blend comprises up to 3times more modacrylic fibers than aramid fibers.

Example 16. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the first fiber blend comprisesapproximately 5-30% aramid fibers, 50-80% modacrylic fibers, and 10-40%cellulosic fibers.

Example 17. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the second fiber blend comprises atleast 60% non-FR cellulosic fibers.

Example 18. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the aramid fibers of the second fiberblend constitute 40% or less of the second fiber blend.

Example 19. The fabric of any of the preceding or subsequent examples orcombination of examples, wherein the fabric is a woven fabric comprisinga first fabric direction and a second fabric direction opposite thefirst fabric direction, wherein the first yarns are provided only in thefirst fabric direction and the second yarns are provided only in thesecond fabric direction.

Example 20. A garment formed with the fabric of any of the preceding orsubsequent examples or combination of examples, the garment having aface side and a body side, wherein the first side of the fabric isexposed on the face side of the garment and the second side of thefabric is exposed on the body side of the garment.

Different arrangements of the components described above, as well ascomponents and steps not shown or described are possible. Similarly,some features and subcombinations are useful and may be employed withoutreference to other features and subcombinations. Embodiments of theinvention have been described for illustrative and not restrictivepurposes, and alternative embodiments will become apparent to readers ofthis patent. Accordingly, the present invention is not limited to theembodiments described above or depicted in the drawings, and variousembodiments and modifications can be made without departing from thescope of the invention.

We claim:
 1. A fabric formed by first yarns and a second yarns, whereinthe fabric has a first side and a second side opposite the first sideand wherein: i. the first yarns comprise a first fiber blend comprisingaramid fibers, modacrylic fibers, and cellulosic fibers; ii. the aramidfibers and the modacrylic fibers of the first fiber blend constitute atleast 50% of the first fiber blend; iii. the first fiber blend comprisesmore modacrylic fibers than aramid fibers; iv. the second yarnscomprises a second fiber blend that is different from the first fiberblend and that comprises aramid fibers, modacrylic fibers, andcellulosic fibers; v. the second fiber blend comprises at least 60%cellulosic fibers; vi. the second fiber blend comprises more modacrylicfibers than aramid fibers; vii. the first yarns are predominantlyexposed on the first side of the fabric; viii. the second yarns arepredominantly exposed on the second side of the fabric; ix. the fabrichas a char length of at least 6 inches and an afterflame of 2 seconds orless when tested pursuant to AS™ D6413 (2015); x. the fabric has afabric weight between 5 to 7 ounces per square yard, inclusive; and xi.the fabric has an arc rating of at least 8 cal/cm² when tested pursuantto ASTM F1959 (2014).
 2. The fabric of claim 1, wherein the aramidfibers and the modacrylic fibers of the first fiber blend constitute atleast 60% of the first fiber blend.
 3. The fabric of claim 1, whereinthe first fiber blend comprises up to 2 times more modacrylic fibersthan aramid fibers.
 4. The fabric of claim 3, wherein the first fiberblend comprises up to 3 times more modacrylic fibers than aramid fibers.5. The fabric of claim 1, wherein the first fiber blend comprisesapproximately 5-25% aramid fibers, 50-80% modacrylic fibers, and 15-40%cellulosic fibers.
 6. The fabric of claim 1, wherein the cellulosicfibers in the first fiber blend are non-FR lyocell fibers.
 7. The fabricof claim 1, wherein the modacrylic fibers in the first fiber blend areadditive-containing fibers.
 8. The fabric of claim 1, wherein the aramidfibers in the first fiber blend comprise meta-aramid fibers andpara-aramid fibers.
 9. The fabric of claim 1, wherein the second fiberblend comprises at least 70% cellulosic fibers.
 10. The fabric of claim1, wherein the modacrylic fibers and aramid fibers of the second fiberblend constitute 40% or less of the second fiber blend.
 11. The fabricof claim 1, wherein the fabric is a woven fabric comprising a firstfabric direction and a second fabric direction opposite the first fabricdirection, wherein the first yarns are provided only in the first fabricdirection and the second yarns are provided only in the second fabricdirection.
 12. A garment formed with the fabric of claim 1 and having aface side and a body side, wherein the first side of the fabric isexposed on the face side of the garment and the second side of thefabric is exposed on the body side of the garment.
 13. A fabric formedby first yarns and a second yarns, wherein the fabric has a first sideand a second side opposite the first side and wherein: i. the firstyarns comprise a first fiber blend comprising aramid fibers, modacrylicfibers, and cellulosic fibers; ii. the aramid fibers and the modacrylicfibers of the first fiber blend constitute at least 70% of the firstfiber blend; iii. the first fiber blend comprises more modacrylic fibersthan aramid fibers; iv. the second yarns comprises a second fiber blendthat is different from the first fiber blend and that comprises aramidfibers and non-FR cellulosic fibers; v. the second fiber blend is devoidof modacrylic fibers; vi. the second fiber blend comprises at least 50%non-FR cellulosic fibers; vii. the first yarns are predominantly exposedon the first side of the fabric; viii. the second yarns arepredominantly exposed on the second side of the fabric; ix. the fabrichas a char length of at least 6 inches and an afterflame of 2 seconds orless when tested pursuant to AS™ D6413 (2015); x. the fabric has afabric weight between 5 to 7 ounces per square yard, inclusive; and xi.the fabric has an arc rating of at least 8 cal/cm² when tested pursuantto ASTM F1959 (2014).
 14. The fabric of claim 13, wherein the aramidfibers and the modacrylic fibers of the first fiber blend constitute atleast 80% of the first fiber blend.
 15. The fabric of claim 13, whereinthe first fiber blend comprises up to 3 times more modacrylic fibersthan aramid fibers.
 16. The fabric of claim 13, wherein the first fiberblend comprises approximately 5-30% aramid fibers, 50-80% modacrylicfibers, and 10-40% cellulosic fibers.
 17. The fabric of claim 13,wherein the second fiber blend comprises at least 60% non-FR cellulosicfibers.
 18. The fabric of claim 13, wherein the aramid fibers of thesecond fiber blend constitute 40% or less of the second fiber blend. 19.The fabric of claim 13, wherein the fabric is a woven fabric comprisinga first fabric direction and a second fabric direction opposite thefirst fabric direction, wherein the first yarns are provided only in thefirst fabric direction and the second yarns are provided only in thesecond fabric direction.
 20. A garment formed with the fabric of claim13 and having a face side and a body side, wherein the first side of thefabric is exposed on the face side of the garment and the second side ofthe fabric is exposed on the body side of the garment.